C-Channel Panel, Overcast, Stopping and Method

ABSTRACT

A panel includes a core having a top, a bottom, a first side and a second side. The panel includes a first cap disposed on the top. The panel includes a second cap disposed on the bottom. The panel includes a first grid disposed adjacent the first side. The panel includes a second grid disposed adjacent the second side. The first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core. A stopping. An overcast. A method for building a wall.

FIELD OF THE INVENTION

The present invention is related to a panel for building structures thathas cement or concrete applied to it. (As used herein, references to the“present invention” or “invention” relate to exemplary embodiments andnot necessarily to every embodiment encompassed by the appended claims.)More specifically, the present invention is related to a panel forbuilding structures that has cement or mortar or concrete applied to itto build overcasts or stoppings in a mine, and does not have anythingextending through its core.

BACKGROUND OF THE INVENTION

This section is intended to introduce the reader to various aspects ofthe art that may be related to various aspects of the present invention.The following discussion is intended to provide information tofacilitate a better understanding of the present invention. Accordingly,it should be understood that statements in the following discussion areto be read in this light, and not as admissions of prior art.

The construction industry uses prefabricated panels that serve as asupport with the application of cement, such as Gunite or Shotcrete toform building blocks for walls, floors, ceilings or roofs, to name but afew of the possible structures. The present invention is a prefabricatedpanel that is believed to be better than existing panels in terms ofsupporting loads and withstanding forces that are typically experiencedin such structures.

BRIEF SUMMARY OF THE INVENTION

The present invention pertains to a panel. The panel comprises a corehaving a top, a bottom, a first side and a second side. The panelcomprises a first cap disposed on the top. The panel comprises a secondcap disposed on the bottom. The panel comprises a first grid disposedadjacent the first side. The panel comprises a second grid disposedadjacent the second side. The first cap and the second cap and the firstgrid and the second grid defining a frame which envelopes and holds thecore without piercing through the core.

The present invention pertains to an overcast for a mine. The overcastcomprises sidewalls. The overcast comprises decking disposed on thesidewalls. The decking and sidewalls formed of at least one panelcomprising a core having a top, a bottom, a first side and a secondside. The panel comprises a first cap disposed on the top. The panelcomprises a second cap disposed on the bottom. The panel comprises afirst grid disposed adjacent the first side, the first cap and thesecond cap and the first grid and the second grid defining a frame whichenvelopes and holds the core without piercing through the core. Thepanel comprises mortar or concrete disposed on the first grid.

The present invention pertains to a stopping for a tunnel. The stoppingcomprises a plurality of panels. At least two of the panels areconnected together. At least one panel comprises a core having a top, abottom, a first side and a second side. The one panel comprises a firstcap disposed on the top. The one panel comprises a second cap disposedon the bottom. The one panel comprises a first grid disposed adjacentthe first side. The first cap and the second cap and the first grid andthe second grid define a frame which envelopes and holds the corewithout piercing through the core. The one panel comprises mortar orconcrete disposed on the first grid.

The present invention pertains to a method for building a wall. Themethod comprises the steps of placing a first panel in a desiredposition. The first panel comprises a core having a top, a bottom, afirst side and a second side. The first panel comprises a first capdisposed on the top. The first panel comprises a second cap disposed onthe bottom. The first panel comprises a first grid disposed adjacent thefirst side. The first cap and the second cap and the first grid and thesecond grid define a frame which envelopes and holds the core withoutpiercing through the core. There is the step of placing a second paneladjacent the first panel. There is the step of connecting the firstpanel with the second panel. There is the step of applying mortar orconcrete to the first panel and second panel.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, the preferred embodiment of the inventionand preferred methods of practicing the invention are illustrated inwhich:

FIG. 1 shows a frame of the panel of the present invention.

FIG. 2 shows the panel.

FIG. 3 shows a portion of the first cap with the first and second gridsand first and second bars.

FIG. 4 shows a top view of the portion of the first cap.

FIG. 5 shows a side view of the portion of the first cap.

FIG. 6 shows a portion of the first cap.

FIG. 7 shows a clamp and spacer.

FIG. 8 shows the clamp and spacer with the clamp unbent.

FIG. 9 shows a representation of a stopping.

FIG. 10 shows an exploded view of a representation of an overcast.

FIG. 11 is a side view of a representation of an overcast.

FIG. 12 is a side view of a representation of an overcast.

FIG. 13 is an overhead cutaway view of a representation of a mine withan overcast and a stopping.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals refer tosimilar or identical parts throughout the several views, and morespecifically to FIGS. 1 and 2 thereof, there is shown a panel 10. Thepanel 10 comprises a core 12 having a top 14, a bottom 16, a first side18 and a second side 20. The panel 10 comprises a first cap 22 disposedon the top 14. The panel 10 comprises a second cap 24 disposed on thebottom 16. The panel 10 comprises a first grid 26 disposed adjacent thefirst side 18. The panel 10 comprises a second grid 28 disposed adjacentthe second side 20. The first cap 22 and the second cap 24 and the firstgrid 26 and the second grid 28 define a frame 34 which envelopes andholds the core 12 without piercing entirely through the core 12. The onepanel 10 comprises mortar or concrete 83 disposed on the first grid 26.

The panel 10 may include a plurality of first bars 30, for examplepieces of rebar, disposed adjacent the first side 18. The panel 10 mayinclude a plurality of second bars 32, for example pieces of rebar,disposed adjacent the second side 20. The first cap 22 and the secondcap 24 and the first grid 26 and the second grid 28 and if present, thefirst bars 30 and the second bars 32, define a frame 34 which envelopesand holds the core 12 without piercing through the core 12.

The first grid 26 may be attached to the first cap 22 and the second cap24. The second grid 28 may be attached to the first cap 22 and thesecond cap 24. The first bars 30 may be attached to the first cap 22 andthe second cap 24. The second bars 32 may be attached to the first cap22 and the second cap 24. The first cap 22 may have c shaped crosssection defined by a top web 36 and a top first flange 38 and a topsecond flange 40, with the top web 36 disposed on the top 14 of the core12, as shown in FIGS. 2 and 3. The top first flange 38 is disposed onthe first side 18, and the top second flange 40 is disposed on thesecond side 20.

The second cap 24 may have a c shaped cross section defined by a bottomweb 42 and a bottom first flange 44 and a bottom second flange 46, withthe bottom web 42 disposed on the top 14 of the core 12. The bottomfirst flange 44 is disposed on the first side 18, and the bottom secondflange 46 is disposed on the second side 20. Each first bar may beattached to the top first flange 38 and the bottom first flange 44. Eachsecond bar may be attached to the top second flange 40 and the bottomsecond flange 46. The panel 10 may include mortar or concrete disposedon the first grid 26 and on the second grid 28 to a thickness of about1.5 inches or more.

The present invention pertains to an overcast 70 for a mine, as shown inFIGS. 10-13. The overcast 70 comprises sidewalls 71. The overcastcomprises decking 73 disposed on the sidewalls 71. The decking 73 andsidewalls 71 formed of at least one panel At least one panel 10comprises a core 12 having a top 14, a bottom 16, a first side 18 and asecond side 20. The panel 10 comprises a first cap 22 disposed on thetop 14. The panel 10 comprises a second cap 24 disposed on the bottom16. The panel 10 comprises a first grid 26 disposed adjacent the firstside 18. The panel 10 comprises a second grid 28 disposed adjacent thesecond side 20. The first cap 22 and the second cap 24 and the firstgrid 26 and the second grid 28 define a frame 34 which envelopes andholds the core 12 without piercing entirely through the core 12. The onepanel 10 comprises mortar or concrete 83 disposed on the first grid 26.

The present invention pertains to a stopping 69 for a tunnel, as shownin FIG. 9. The stopping 69 comprises a plurality of panels 10. At leasttwo of the panels 10 are connected together. At least one panel 10comprises a core 12 having a top 14, a bottom 16, a first side 18 and asecond side 20. The panel 10 comprises a first cap 22 disposed on thetop 14. The panel 10 comprises a second cap 24 disposed on the bottom16. The panel 10 comprises a first grid 26 disposed adjacent the firstside 18. The panel 10 comprises a second grid 28 disposed adjacent thesecond side 20. The first cap 22 and the second cap 24 and the firstgrid 26 and the second grid 28 define a frame 34 which envelopes andholds the core 12 without piercing entirely through the core 12. The onepanel 10 comprises mortar or concrete 83 disposed on the first grid 26.

The present invention pertains to a method for building a wall. Themethod comprises the steps of placing a first panel 10 in a desiredposition. The first panel 10 comprises a core 12 having a top 14, abottom 16, a first side 18 and a second side 20. The panel 10 comprisesa first cap 22 disposed on the top 14. The panel 10 comprises a secondcap 24 disposed on the bottom 16. The panel 10 comprises a first grid 26disposed adjacent the first side 18. The panel 10 comprises a secondgrid 28 disposed adjacent the second side 20. The first cap 22 and thesecond cap 24 and the first grid 26 and the second grid 28 define aframe 34 which envelopes and holds the core 12 without piercing entirelythrough the core 12. There is the step of placing a second paneladjacent the first panel 10. There is the step of connecting the firstpanel 10 with the second panel. There is the step of applying mortar orconcrete to the first panel and second panel.

In the operation of the invention, the panel 10 is formed by placing thefirst cap 22 on the top 14 of the core 12 and the second cap 24 on thebottom 16 of the core 12. Each cap is 20 feet long, the web of the capis 4.75 inches wide, and each flange is 2 inches wide. Each cap is madeof 18 gauge steel. The first grid 26 is then placed on the first side 18of the core 12 by having the top 14 of the first grid 26 inserted intoraised slots 48 on the top first flange 38 at intervals along itslength. Clamps 50 are then screwed down into the top first flange 38 atintervals along its length to hold the top 14 of the first grid 26 inplace. Alternatively, the top 14 of the first grid 26 can be welded orbraised or soldered to the top first flange 38 of the first cap 22. Eachgrid is formed of welded wire mesh made of 11 gauge steel, where themesh is 2 inch by 2 inch. The core 12 is a 2.5 inch or 4 inch thickexpanded polystyrene foam as per ASTM C578, incorporated by referenceherein, and which has a flame spread index of 25 or less. The core 12made of EPS is an insulation core 12. The length of the panel 10 isabout 20 feet long and 4 feet high.

The bottom 16 of the first grid 26 is then inserted into raised slots 48on the bottom first flange 44 at intervals along its length. The slots48 facilitate the proper positioning and alignment of the grid. Clamps50 are then screwed down into the bottom first flange 44 at intervalsalong its length to hold the bottom 16 of the first grid 26 in place.Alternatively, the bottom 16 of the first grid 26 can be welded orbraised or soldered to the bottom first flange 44 of the first cap 22.The second grid 28 is then placed on the second side 20 of the core 12in the same manner as the first grid 26 is placed on the first side 18.

Spacers 52, as shown in FIG. 5, with the clamps 50 are positioned atintervals on the top first and second flanges and bottom first andsecond flanges along their length to maintain a gap 56 between the gridsand the respective surfaces of the core 12 for the cement to properlyform on the core 12 and grids, as shown in FIG. 2. Each clamp 50 has a cportion 54 of metal that defines a clamp opening 58 through which a gridwire 60 of the top row of grid wires 60 of the first grid 26 extends, asshown in FIGS. 4 and 5. The c portion 54 is a rectangular strip of metalabout 2 inches long and about 0.5 inches wide and 0.125 inches thick.The c portion 54 is formed by basically being bent in half. A bottom 16of the c portion 54 is defined by a first leg 62 and a second leg 64through which a screw 66 extends to capture the grid wire 60 in theclamp opening 58 when the screw 66 is tightened down onto the top firstflange 38, as shown in FIGS. 5, 7 and 8. There is a metal spacer 52, inthe form of a block or cylinder that is about 0.5 inches long and about0.25 inches in diameter disposed between the clamp 50 and the top firstflange 38. The screw 66 extends through a spacer 52 hole and the firstand second legs 62, 64 and the top first flange 38 to hold the firstgrid 26 and clamp 50 and spacer 52 in place. The screw 66 is long enoughto also penetrate about an inch into the core 12 when tightened down.This assembly is repeated at several locations along the top firstflange 38, the top second flange 40, the bottom first flange 44 and thebottom second flange 46 to secure the first grid 26 at the desireddistance from the first side 18 of the core 12, and the second grid 28at the desired distance from the second side 20 of the core 12. Thefirst grid 26 and second grid 28 serve to hold the mortar or concretethat is placed on the panel 10. Typically, concrete in the form ofGunite or Shotcrete is sprayed onto each side of the panel 10, as iswell-known in the art.

The top 14 of each piece of rebar on the first side 18 is welded orbraised to or inserted through a flange hole 68 in the top first flange38, as shown in FIGS. 1, 2 and 6, and the bottom 16 of each piece ofrebar on the first side 18 is also welded or braised to or insertedthrough a flange hole 68 in the bottom first flange 44. Similarly, thetop 14 of each piece of rebar on the second side 20 is welded or braisedto or inserted through the top second flange 40, and the bottom 16 ofeach piece of rebar on the second side 20 is welded or braised to orinserted through the bottom second flange 46. Each piece of rebar istied or coupled to the grid at several locations along the piece ofrebar's length with ties 72. The pieces of rebar serve to add structuralstrength, rigidity and integrity to the panel 10 so the panel 10 canwithstand the loads typically expected to be placed on it. The pieces ofrebar also serve the dual purpose of being a spacer 52 between the gridand the core 12 to maintain the gap 56 between the grid and the core 12for the Gunite to better build up a cement layer. The rebar has a ⅜ inchdiameter and is about 4 feet 1 inch long. A piece of rebar is typicallyspaced every three to four feet along the length of the panel. The rebaris typically used when the panel is used for decking in an overcast. Ina stopping, or side wall and wing wall of an overcast, when the panel isvertically oriented relative to the ground, the rebar does not have tobe used.

The panel 10 may be used for any type of building or constructionapplications. Underground, in a tunnel, such as that found in a mine,the panel 10 can be used for ventilation structures that includestoppings, overcasts, undercasts and even seals.

In the construction of a stopping 69, as shown in FIG. 9, the site inthe mine would first be prepared, as is well-known in the art. A firstpanel 10 is placed alongside a seam extending essentially perpendicularfrom the seam across the tunnel. Holes are drilled in the flooralongside the panel 10. Resin capsules are inserted into the holes andthen pieces of rebar are inserted into the holes which extend from theground. Each piece of rebar is then tied to the grid to which it isalongside. In similar fashion, if the panel 10 placed on the ground doesnot extend entirely across the tunnel to the seam on the opposite side,a second panel 100, or at least a portion of a second panel 100 isplaced alongside the first panel 10 already placed on the ground toextend across the tunnel between the opposing seams. The first grid 26on the first panel 10 and the first grid 26 of the second panel 100 arecoupled together either with ties 72 or couples to link the first panel10 to the second panel 100. If the width of the tunnel is less than thelength of a single panel 10, then the single panel 10 is cut to lengthto essentially extend across the tunnel between the opposing seams.

Depending on the height of the tunnel, additional panels may need to beplaced on top of the first panel 10 and the second panel 100, if thereis one. In similar fashion, if a third panel 200 is necessary to closethe area of the tunnel above the first panel 10, the third panel 200 isplaced on top of the first panel 10 and the first grid 26 of the firstpanel 10 and the first grid 26 of the third panel 200 are coupled withcouplers or ties 72. Similarly, if a fourth panel 300, or a portion of afourth panel 300 is needed to be placed on any second panel 100, thenthe fourth panel 300 is coupled in similar manner to the third panel 200alongside it and the second panel 100 below it.

Once the width of the tunnel is essentially closed off, if it is sodesired, holes are drilled into the roof of the tunnel alongside thefront of the third panel 200 and fourth panel 300, if they are present,or just the first panel 10 if it is the only panel. Resin capsules canbe inserted into the holes and pieces of rebar then inserted into theholes so they extend from the roof. The pieces of rebar extending fromthe roof are then tied or coupled to the first grid 26 to which they arealongside. In similar fashion the second side 20 of the stopping 69formed of the first panel 10 and any additional panels are connected torebar extending from the floor alongside the second side 20, and ifdesired from rebar extending from the ceiling. In addition, as explainedin regard to the first side 18, the second grid 28 of each panel 10 iscoupled together. Gunite is then sprayed on each side of the panels so alayer of at least 1.5 inches, and typically 2 inches, are formed oneither side of the panels that make up the stopping 69. The Gunite isalso applied along the edges of the panels alongside the seams so anyopenings or aps between the sides of the panels or panel, are closed offand create a seal, preventing any airflow past the stopping. Theapplication of Gunite is well-known in the art.

In a similar manner an overcast 70, or undercast can be formed in anintersection of tunnels, for instance in a mine. See FIGS. 10-13. Thesidewalls 71 are formed in the same way as described above for thestopping 69. The decking 73 of the overcast 70 is formed by placingpanels flat alongside each other horizontally across the width of thetunnel with their sides disposed on top of the sidewalls 71 andsupported by the sidewalls 71. The panels alongside each other form thedecking 73 are tied or coupled together through their respective grids,first grid to first grid and second grid to second grid.

If one or more wing walls 75 are needed to close off air flow around theside walls 71, the wing walls 75 are built the same way as the walls forstopping, with the wing wall 75 built high enough to reach the seam.Pieces of rebar may be inserted into holes drilled into the seam withresin capsules to hold the rebar. The wing wall 75 can be tied to therebar pieces. The sidewalls 71 and decking 73 and any wing walls 75 andgaps between them and the seams are sprayed with Gunite to a thicknessof at least 1.5 inches and preferably 2 inches, to form an air tightseal and solid support structure that can withstand loads and forces ofat least 15 psi.

Although the invention has been described in detail in the foregoingembodiments for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be described by thefollowing claims.

1. A panel comprising: a core having a top, a bottom, a first side and asecond side; a first cap disposed on the top; a second cap disposed onthe bottom; a first grid disposed adjacent the first side; and a secondgrid disposed adjacent the first side, the first cap and the second capand the first grid and the second grid defining a frame which envelopesand holds the core without piercing through the core.
 2. The panel ofclaim 1 wherein the first grid is attached to the first cap and thesecond cap.
 3. The panel of claim 2 wherein the second grid is attachedto the first cap and the second cap.
 4. The panel of claim 3 wherein thefirst cap has a c shaped cross section defined by a top web and a topfirst flange and a top second flange, with the top web disposed on thetop of the core, the top first flange disposed on the first side, andthe top second flange disposed on the second side.
 5. The panel of claim4 wherein the second cap has a c shaped cross section defined by abottom web and a bottom first flange and a bottom second flange, withthe bottom web disposed on the top of the core, the bottom first flangedisposed on the first side, and the bottom second flange disposed on thesecond side.
 6. The panel of claim 5 including mortar or concretedisposed on the first grid.
 7. The panel of claim 6 including aplurality of first bars disposed adjacent the first side; and aplurality of second bars disposed adjacent the second side, the firstcap and the second cap and the first grid and the second grid and thefirst bars and the second bars defining a frame which envelopes andholds the core without piercing through the core.
 8. The panel of claim7 wherein the first bars are attached to the first cap and the secondcap.
 9. The panel of claim 8 wherein the second bars are attached to thefirst cap and the second cap.
 10. The panel of claim 9 wherein eachfirst bar is attached to the top first flange and the bottom firstflange.
 11. The panel of claim 10 wherein each second bar is attached tothe top second flange and the bottom second flange.
 12. An overcast fora miner comprising: sidewalls; decking disposed on the sidewalls, thedecking and sidewalls formed of at least one panel comprising: a corehaving a top, a bottom, a first side and a second side; a first capdisposed on the top; a second cap disposed on the bottom; a first griddisposed adjacent the first side, the first cap and the second cap andthe first grid and the second grid defining a frame which envelopes andholds the core without piercing through the core; and mortar or concretedisposed on the first grid.
 13. A stopping for a tunnel comprising: aplurality of panels, at least two panels are connected together, atleast one panel comprising: a core having a top, a bottom, a first sideand a second side; a first cap disposed on the top; a second capdisposed on the bottom; a first grid disposed adjacent the first side,the first cap and the second cap and the first grid and the second griddefining a frame which envelopes and holds the core without piercingthrough the core; and mortar or concrete disposed on the first grid. 14.A method for building a wall comprising the steps of: placing a firstpanel in a desired position, the first panel comprising a core having atop, a bottom, a first side and a second side; a first cap disposed onthe top; a second cap disposed on the bottom; a first grid disposedadjacent the first side; and a second grid disposed adjacent the firstside, the first cap and the second cap and the first grid and the secondgrid defining a frame which envelopes and holds the core withoutpiercing through the core; placing a second panel adjacent the firstpanel; connecting the first panel with the second panel; and applyingmortar or concrete to the first panel and second panel.